200213-14.pmd

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Installation and Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ..........A13 (Sept 06) to A14 (Nov 06)

Caradon Ideal Limited reserve the right to vary specification without notice

Page 8, Table 4 - Balanced Flue Terminal Position

Item no. 1 updated to include above opening.

Page 12, Frame 6 - Water Treatment

New contact details for Sentinel Performance Solutions.

Page 14, Frame 9 - Unpacking

Hardware Pack - new items E, L & M.

Page 20, Frame 21 - Fitting the Piping Frame and Valves

New pictorial image of compression gas cock.

Page 23, Frame 25 - Mounting the Boiler

Item no. 6, Fibre washer is now blue not green.

Page 24 - Frame 27, Water Connections CH

New pictorial image of compression gas cock.

Page 25 - Frame 28, Water Connections DHW

New pictorial image of compression gas cock.

Page 25 - Frame 29, Gas Connection

Fibre washer is now blue not green.
New pictorial image of compression gas cock.

Page 48 - Frame 72, Draining the Boiler

New pictorial image of compression gas cock.

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isar -

Installation and Servicing

GENERAL

isar

HE24

HE30

HE35

Gas supply

2H - G20 - 20mbar

Gas Supply Connection

Rc 1/2 (1/2" BSP female)

Injector Size

Stereomatic 5.6mm dia.

5.7mm dia

Inlet Connection

Domestic Hot Water

15mm copper compression

Outlet Connection

Domestic Hot Water

15mm copper compression

Flow Connection

Central Heating

22mm copper compression

Return Connection

Central Heating

22mm copper compression

Flue Terminal Diameter

mm (in)

100 (4)

Average Flue Temp-Mass Flow Rate

(DHW)

C-10g/s

C - 12 g/s

C-14g/s

Maximum Working Pressure (Sealed Systems)

bar (lb/in

)

2.65 (38.5)

Maximum Domestic Hot Water Inlet Pressure

bar

(lb/in

)

10.0 (145)

Minimum Domestic Hot Water Inlet Pressure

bar

(lb/in

)

0.5 (7)

Electrical Supply

230 V ~ 50 Hz.

Power Consumption

148 W

152 W

Fuse Rating

External : 3A Internal : T3.15A L250 V

Water content

Central Heating

litre (gal)

2.0 (0.44)

Domestic Hot Water

0.5 (0.11)

Packaged Weight

kg (lb)

52 (115)

53 (117)

Maximum Installation Weight

kg (lb)

42.5 (94)

43 (95)

43.5 ( 96)

Boiler Casing Size

Height

mm (in)

687 (27)

Width

mm (in)

390 (15 3/8)

Depth

mm (in)

278 (11)

Table 1 - General Data

Note. Gas consumption is calculated using a
calorific value of 38.7 MJ/m

(1038 Btu/ft

) gross

or 34.9 MJ/m

(935 Btu/ft

) nett

To obtain the gas consumption at a different
calorific value:
a. For l/s- divide the gross heat input (kW) by

the gross C.V. of the gas (MJ/m

)

b. For ft

/h - divide the gross heat input (Btu/h)

by the gross C.V. of the gas (Btu/ft

)

Key to symbols
GB = United Kingdom

IE = Ireland

(Countries of destination)

PMS = Maximum operating pressure of water
C

= A room sealed appliance designed for connection via ducts to a

horizontal or vertical terminal, which admits fresh air to the burner
and discharges the products of combustion to the outside through
orifices which, in this case, are concentric. The fan is up stream
of the combustion chamber.

= An appliance designed for use on 2nd Family gas, Group H only.

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which

it has been calculated have been certified by a notified body.

CAUTION.

To avoid the possibility of injury during the installation, servicing or cleaning of

this appliance care should be taken when handling edges of sheet steel components

Table 2 - Performance Data - Central Heating

Maximum DHW Input :

HE24

HE30

HE35

Nett CV

24.3

30.2

36.0

(Btu/h) (82 900) (103 000) (122 800)

Gross CV

27.0

33.5

39.9

(Btu/h) (92 100) (114 400) (136 200)

Gas Consumption

l/s

0.7

0.87

1.03

(ft

/h)

(89.0)

(110)

(131)

Maximum

23.4

29.3

35.2

DHW Output

(Btu/h) (80 000) (100 000) (120 000)

DHW Flow Rate

l/min

9.6

12.0

14.4

at 35°C temp. rise.

(gpm)

(2.1)

2.6

(3.2)

DHW Specific Rate

l/min

11.2

14.0

16.8

(gpm)

(2.5)

(3.1)

(3.7)

Table 3 - Performance Data - Domestic Hot Water

Boiler Input :

Max.

Min.

Boiler Input `Q'

Nett CV

24.4

9.1

(Btu/h)

(83 300)

(31 000)

Gross CV

27.1

10.1

(Btu/h)

(92 500)

(34 400)

Gas Consumption

l/s

0.70

0.26

(ft

/h)

(89.0)

(33.1)

Boiler Output :

Non Condensing

23.4

8.8

C Mean Water temp.

(Btu/h)

(80 000)

(30 000)

Condensing

25.1

9.6

C Mean Water temp.

(Btu/h)

(85 700)

(32 800)

Seasonal efficiency*

(SEDBUK)

Band A [90.1]%

NOx Classification

Class 5

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Installation and Servicing

GENERAL

Boiler size

G.C. Appliance No.

PI No.

(Benchmark No.)

HE24

47 348 31

0063 BO 3317

HE30

47 348 30

0063 BO 3317

HE35

47 348 29

0063 BO 3317

CONTENTS

Air Supply ....................................................................... 8
Benchmark Commissioning Checklist ..................... 62
Boiler Clearances ......................................................... 9
Boiler Exploded Diagram ............................................ 13
Condensate Drain ........................................... 10, 21-22
Electrical Connections ............................................... 27
Electrical Supply ......................................................... 10
Extension Ducts - Fitting ............................................. 19
Fault Finding ........................................................... 52-56
Flow Wiring Diagram .................................................. 30
Flue Fitting .................................................................... 18
Flue Installation ............................................................. 8
Gas Safety Regulations ................................................ 7
Gas Supply ..................................................................... 8
Installation ............................................................. 12-33
Mandatory Requirements ....................................... 7-10
Pump .......................................................................... 49
Safe Handling ................................................................ 6
Servicing ................................................................ 34-38
Short List of Parts ....................................................... 57
Thermostatic Radiator Valves ................................... 10
Water and Systems ........................................... 8,10-12
Water Connections ............................................... 24-25
Water Treatment ......................................................... 12
Wiring Diagrams ................................................... 27-30

isar

Natural Gas only

Destination Country: GB, IE

oiler

Page

Make and model ....................................................... 5
Appliance serial no. on data badge ...................... 13
SEDBUK No. % ......................................................... 4

Controls

Time and temperature control to heating ............. 28
Time and temperature control to hot water .......... 28
Heating zone valves .............................................. n/a
TRV's ...................................................................... 10
Auto bypass ........................................................... 10
Boiler interlock ....................................................... 10

For all boilers

Flushing to BS.7593 .............................................. 12
Inhibitor .................................................................. 12

Central heating mode
Heat input ................................................to be calculated

For assistance see Technical Helpline on the back page

Page

Burner operating pressure .................................... n/a
Central heating flow temp. ...... measure and record
Central heating return temp. ... measure and record

For combination boilers only

Scale reducer ......................................................... n/a

Hot water mode

Heat input .......................................... to be calculated
Max. operating burner pressure .............................. n/a
Max. operating water pressure ........... measure & record
Cold water inlet temp ..................... measure & record
Hot water outlet temp. .................... measure & record
Water flow rate at max. setting ............ measure & record

For condensing boilers only

Condensate drain .................................................. 21

For all boilers: complete, sign & hand over to customer

For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the
manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

NOTE TO THE INSTALLER: COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

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Installation and Servicing

GENERAL

INTRODUCTION

The isar range of boilers are model is a wall mounted, full sequence,
automatic spark ignition, low water content, fanned flue, high efficiency,
condensing, combination gas boilers.
Note.Due to the high efficiency of the boiler a plume of water vapour will form

at the terminal during operation.

Central heating (CH) output is fully modulating with a range of 8.8 to 23.4kW
(30,000 to 80,000 Btu/h)
Instantaneous domestic hot water (DHW) output is also fully modulating with
a maximum of :
HE24 24.4kW (80,000 Btu/h)
HE30 29.3kW (100,000 Btu/h)
HE35 35.2kW (120,000 Btu/h)
The boiler is supplied fully assembled with DHW plate heat exchanger,
diverter valve, circulating pump, pressure gauge, safety valve and CH
expansion vessel.
Variable CH and DHW temperature controls are fitted on the user control and
the boiler features a DHW preheat facility.
The boiler casing is of white painted mild steel with the user controls
capable of being mounted remotely from the boiler if the option is required.
The boiler temperature controls are visible at the bottom RHS of the front
panel.
The heat exchanger is of cast aluminium.
The boiler is suitable for connection to fully pumped, sealed water systems
ONLY. Adequate arrangements for completely draining the system by
provision of drain cocks MUST be provided in the installation pipework.
Pipework from the boiler is routed downwards as standard, but may be
routed upwards behind the boiler using the stand-off frame (supplied in a
separate kit).

OPERATION

With no demand for CH, the boiler fires only when DHW is drawn off, or
periodically for a few seconds without any DHW draw-off, in order to maintain
the DHW calorifier in a heated condition.
When there is a demand for CH, the heating system is supplied at the
selected temperature of between 30

C and 82

C, until DHW is drawn off.

The full output from the boiler is then directed via the diverter valve to the
plate heat exchanger to supply a nominal DHW draw-off of
HE24 9.6 l/min at 35

C temperature rise.

HE30 12 l/min at 35

C temperature rise.

HE35 14.4 l/min at 35

C temperature rise.

The DHW draw off rate specified above is the nominal that the boiler flow
regulator will give. Due to system variations and seasonal temperature
fluctuations DHW flow rates/temperature rise will vary, requiring adjustment
at the draw off tap.
At low DHW draw-off rate the maximum temperature is limited to 65

C by the

modulating gas control.
Refer also to Frame 1 - 'Boiler Water Circuit Diagrams'
The boiler features a comprehensive diagnostic system which gives detailed
information on the boiler status when operating, and performance of key
components to aid commissioning and fault finding.

SAFE HANDLING

This boiler may require 2 or more operatives to move it to its installation site,
remove it from its packaging base and during movement into its installation
location. Manoeuvring the boiler may include the use of a sack truck and
involve lifting, pushing and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when
performing these tasks and the following precautions should be considered:
·

Grip the boiler at the base.

Be physically capable.

Use PPE as appropriate, e.g. gloves, safety footwear.

BOILER WATER
CIRCUIT DIAGRAMS

Central Heating Circuit

Expansion
vessel

Automatic
air vent

Gas valve

Plate heat
exchanger

Pump

Safety
relief valve

Condensate
'S' trap

Diverter
valve

Water
pressure
gauge

Sump

Fan

Burner

CH Flow

Gas

Condensate

drain

Discharg

pipe

CH Return

Domestic Hot Water Circuit

Expansion
vessel

Automatic
air vent

Heat
exchanger

Gas valve

Pump

Safety
relief valve

Condensate
'S' trap

Diverter
valve

Water
pressure
gauge

Sump

Fan

Burner

DHW Hot out

Gas

Condensate drain

Discharge pipe

Ecl 2768

DHW Cold in

Plate heat
exchanger

Heat
exchanger

During all manoeuvres and handling actions, every
attempt should be made to ensure the following
unless unavoidable and/or the weight is light.
·

Keep back straight.

Avoid twisting at the waist.

Avoid upper body/top heavy bending.

Always grip with the palm of the hand.

Use designated hand holds.

Keep load as close to the body as possible.

Always use assistance if required.

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Installation and Servicing

GENERAL

SAFETY

Current Gas Safety (installation and use) regulations or rules
in force:

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.

In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
·

Gas Safety (Installation and Use) Regulations

The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (northern Ireland).

The Water Fittings Regulations or Water byelaws in
Scotland.

The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent
Person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5440:1

Flues (for gas appliances of rated input not
exceeding 70 kW).

BS. 5440:2

Ventilation (for gas appliances of rated input not
exceeding 70 kW).

BS. 5449

Forced circulation hot water systems.

BS. 5546

Installation of gas hot water supplies for
domestic purposes (2nd Family Gases)

BS. 6798

Installation of gas fired hot water boilers of rated
input not exceeding 70 kW.

BS. 6891

Low pressure installation pipes.

Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer's notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Caradon Ideal Limited in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Limited could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler or its
manufacture.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment.
The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary, unless
required by the local authority.
For electrical safety reasons there must be no access available
from the back of the boiler.
The boiler must not be fitted outside.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should
be fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.
Bathroom Installations
This appliance is rated IP20.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of the
current IEE (BS.7671) Wiring Regulations and, in Scotland, the
electrical provisions of the building regulations applicable in
Scotland, with respect to the installation of the boiler in a room
or internal space containing a bath or shower. For IE reference
should be made to the current ETCI rules for electrical
installations and I.S. 813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Compartment Installations
A compartment used to enclose the boiler should be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided

that it is modified for the purpose.
In both cases, details of essential features of cupboard /

compartment design, including airing cupboard installation,

are to conform to the following:

BS 6798 (No cupboard ventilation is required - see `Air

Supply' for details).
The position selected for installation MUST allow adequate

space for servicing in front of the boiler.

OPTIONAL EXTRA KITS

Flue Extension Ducts. (1000mm long).
HE24-upto 6m
HE30-upto 6m
HE35-upto 3m
Flue Finishing Kit.
90

Elbow Kit (maximum per installation).

HE24-upto 4 elbows
HE30-upto 4 elbows
HE35-upto 2 elbows

Elbow Kit (maximum per installation).

HE24-upto 4 elbows
HE30-upto 4 elbows
HE35-upto 2 elbows

Roof Flue Kit (to a maximum of 8m).
HE24-upto 8m
HE30-upto 8m
HE35-upto 5m
Powered Vertical Flue Kit (to a maximum primary flue
length of 8m + a maximum secondary flue length of 6m)

HE24

HE30

HE35

Primary flue (m)

Secondary flue (m)

Twin Fluing Kit (up to a maximum of 46m combined total
flue and airducts)
Remote User Controls Kit
Boiler Stand-off Kit
Siphon Kit
Valve Cover Kit

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isar -

Installation and Servicing

GENERAL

For the minimum clearances required for safety and

subsequent service, see the wall mounting template and
Frame 2. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.

GAS SUPPLY

The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an
adequate supply of gas. An existing service pipe must NOT be
used without prior consultation with the local gas supplier.
The boiler MUST be installed on a gas supply with a governed
meter only.
A gas meter can only be connected by the local gas supplier or
by a CORGI registered engineer. In IE by a competent person.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required.
N.B.

The principle of the 1:1 gas valve ensures that the isar

HE range is able to deliver it's full output at inlet pressures
down to 14mb. However if dynamic pressures below 20mb are
experienced ensure this is adequate for ALL other gas
appliances in the property.

IMPORTANT.

Installation pipes must be fitted in accordance with BS.6891. In
IE refer to IS.813:2002. Pipework from the meter to the boiler
MUST be of an adequate size, i.e. no longer than 20m and not
less than 15mm O.D.

The complete installation MUST be tested for gas soundness
and purged as described in the above code.

FLUE INSTALLATION

Pluming will occur at the terminal so terminal positions where
this could cause a nuisance should be avoided.
The flue must be installed in accordance with the
recommendations of BS. 5440-1: 2000.
In IE refer to I.S. 813:2002.
The following notes are intended for general guidance:
1. The boiler MUST be installed so that the terminal is exposed

to external air.

2. It is important that the position of the terminal allows the free

passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to

obstructions and ventilation openings are specified in
Table 4.

4. Where the lowest part of the terminal is fitted less than 2m

(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard.
Terminal guards are available from boiler suppliers. (Ask for
TFC flue guard model no. K6 - round, plastic coated). In
case of difficulty contact:
Grasslin (UK) Ltd.

Tel. + 44 (0) 01732 359 888

Tower House, Vale Rise

Fax. + 44 (0) 01732 354 445

Tonbridge. Kent TN9 1TB

www.tfc-group.co.uk

Ensure that the guard is fitted centrally.

5. The flue assembly shall be so placed or shielded as to

prevent ignition or damage to any part of any building.

6. The air inlet/products outlet duct and the terminal of the

boiler MUST NOT be closer than 25mm (1") to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS. 5440-1:2000.

IMPORTANT. It is absolutely essential to ensure, in practice,
that products of combustion discharging from the terminal
cannot re-enter the building or any other adjacent building
through ventilators, windows, doors, other sources of natural
air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF,
labelled as 'unsafe' until corrective action can be taken.

TERMINAL

The terminal assembly can be adapted to accommodate
various wall thicknesses. Refer to Frame 12 .

AIR SUPPLY

It is NOT necessary to have a purpose-provided air vent in the
room or internal space in which the boiler is installed. Neither
is it necessary to ventilate a cupboard or compartment in which
the boiler is installed, due to the low surface temperatures of
the boiler casing during operation; therefore the requirements
of BS 6798, Clause 12, and BS 5440:2 may be disregarded.

WATER CIRCULATION SYSTEM

IMPORTANT.

A minimum length of 1 metre of copper pipe MUST be fitted to
both flow and return connections from the boiler before
connection to any plastic piping.

The central heating system should be in accordance with
BS.6798 and, in addition, for smallbore and microbore
systems, BS.5449.

WATER TREATMENT - see Frame 6

Flue Terminal Positions

Min. Spacing*

1. Directly below, above or alongside an opening

window, air vent or other ventilation opening.

300mm (12")

2. Below guttering, drain pipes or soil pipes.

25mm ( 1")*

BS5440-1 2000

75mm (3")

3. Below eaves.

25mm (1")*

BS5440-1 2000

200mm (8")

4. Below balconies or a car port roof.

25mm (1")*

BS5440-1 2000

200mm (8")

5. From vertical drain pipes or soil pipes.

25mm (1")*

BS5440-1 2000

150mm (6")

6. From an internal or external corner or to a

25mm (1")*

boundary along side the terminal.

BS5440-1 2000

300mm (12")

7. Above adjacent ground, roof or balcony level.

300mm (12")

8. From a surface or a boundary facing the terminal.

600mm (24")

9. From a terminal facing a terminal.

1,200mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling.

1,200mm (48")

11. Vertically from a terminal on the same wall.

1,500mm (60")

12. Horizontally from a terminal on the wall.

300mm (12")

Vertical Terminals

13. Above the roof pitch with roof slope of all angles. 300mm (12")

Above flat roof.

300mm (12")

14. From a single wall face.

600mm (24")

From corner walls.

1000mm (40")

Twin Flue Applications

15. Centre distance between air inlet and flue

outlet ducts.

120mm (5")

Table 4 - Balanced Flue Terminal Position

* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2000 dimensions must be followed.

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Installation and Servicing

GENERAL

BOILER DIMENSIONS, SERVICES & CLEARANCES

all dimensions in mm (in)

The boiler connections are made on the boiler piping frame.
Refer to Frames 27-29.
The following minimum clearances must be maintained for
operation and servicing.
Additional space will be required for installation, depending
upon site conditions.
Side and Rear Flue
a. Provided that the flue hole is cut accurately, e.g. with a core

drill, the flue can be installed from inside the building
where wall thicknesses do not exceed 600mm (24").

Front clearance
The minimum front clearance when built in to a cupboard is 5mm
(1/4") from the cupboard door but 450mm (17 3/4") overall
clearance is still required, with the cupboard door open, to allow for
servicing.
N.B. The boiler will not fit into a standard depth wall unit. In order for
it to do so the plastic fascia should be removed. See Frame 39.

Bottom clearance
Bottom clearance after installation can be reduced to 5mm.
However, 100mm must be available for servicing.

Where the space into which the boiler is going to be
installed is less than the length of flue required the flue
must be fitted from the outside.

Installation from inside ONLY
b. If a core boring tool is to be used inside the building the

space in which the boiler is to be installed must be at least
wide enough to accommodate the tool.

REAR FLUE ONLY

MIN. Top clearance required = 145 mm (5

3/4

SIDE FLUE ONLY

Horizontal length of flue

Top clearance

from centre line of boiler

required (MIN.)

to outside wall

Dim. A

HE24

HE30

HE35

0.5 m

160 mm (6

5/16

1.0 m

170 mm (6

11/16

)

1.5 m

185 mm (7 1

1.5 m

200 mm ( 7

7/8

2.5 m

210 mm (8 1

3.0 m

225 mm (8

7/8

3.5 m

N/A

250 mm (9

7/8

4.0 m

N/A

260 mm (10

1/4

4.5 m

N/A

265 mm (10

7/16

5.0 m

N/A

275 mm (10

13/16

5.5 m

N/A

290 mm (11

3/8

6.0 m

N/A

300 mm (11

13/16

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Installation and Servicing

GENERAL

General

1. The installation must comply with all relevant national and

local regulations.

2. The installation should be designed to work with flow

temperatures of up to 82

3. All components of the system must be suitable for a working

pressure of 3 bar and temperature of 110

C. Extra care should

be taken in making all connections so that the risk of leakage
is minimised.

The following components are incorporated within the
appliance:

a. Circulating pump.

b. Safety valve, with a non-adjustable preset lift pressure of

3 bar.

c. Pressure gauge, covering a range of 0 to 6 bar.

d. An 8-litre expansion vessel, with an initial charge pressure

of 0.75 bar.

4. 'Make-up' Water. Provision must be made for replacing water

loss from the system, either :

a. From a manually filled 'make-up' vessel with a readily

visible water level. The vessel should be mounted at
least 150mm above the highest point of the system and
be connected through a non-return valve to the system,
fitted at least 150mm below the 'make-up' vessel on the
return side of the radiators.

Notes

a. The method of filling, refilling, topping up or flushing

sealed primary hot water circuits from the mains via a
temporary hose connection is only allowed if acceptable
to the local water authority.

b. Antifreeze fluid, corrosion and scale inhibitor fluids

suitable for use with boilers having aluminium heat
exchangers may be used in the central heating system.

Advice should be sought from a local water treatment
company.

BOILER CONTROL INTERLOCKS

Caradon Ideal Limited recommend that heating systems
utilising full thermostatic radiator valve control of temperature
in individual rooms should also be fitted with a room
thermostat controlling the temperature in a space served by
radiators not fitted with such a valve as stated in BS. 5449.

Central heating systems controls should be installed to
ensure the boiler is switched off when there is no demand
for heating or hot water.

When thermostatic radiator valves are used, the space
heating temperature control over a living / dining area or
hallway having a heating requirement of at least 10% of the
boiler heat output should be achieved using a room
thermostat, whilst other rooms are individually controlled by
thermostatic radiator valves. However, if the system employs
thermostatic radiator valves on all radiators, or two port
valves without end switches, then a bypass circuit must be
fitted with an automatic bypass valve to ensure a flow of
water should all valves be in the closed position.

ELECTRICAL SUPPLY

WARNING.
This appliance must be earthed.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply. For IE reference should be made to
the current ETCI rules for electrical installations.

The point of connection to the mains should be readily
accessible and adjacent to the boiler.

CONDENSATE DRAIN

Refer to Frames 22 & 49.

A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and fittings in
the condensate drainage system MUST be made of plastic - no
other materials may be used.

IMPORTANT.

Any external runs must be insulated

The drain outlet on the boiler is standard 21.5mm (3/4") overflow
pipe.

SYSTEM REQUIREMENTS - Central Heating

Safety valve setting

bar

3.0

Vessel charge pressure

bar

0.5 to 0.75

System pre-charge pressure bar

None

1.0

System volume

Expansion vessel

(litres)

volume (litres)

1.6

1.8

3.1

3.7

4.7

5.5

100

6.3

7.4

125

7.8

9.2

150

9.4

11.0

175

10.9

12.9

190

11.9

14.0

200

12.5

14.7

250

15.6

18.4

300

18.8

22.1

For other system volumes
multiply by the factor across

0.063

0.074

b. Where access to a 'make-up' vessel would be difficult,

by pre-pressurisation of the system.

The maximum cold water capacity of the system
should not exceed 143 litres, if not pressurized.
However, if the system is to be pressurized, the
efficiency of the expansion vessel will be reduced and
a larger vessel (or smaller system volume) may be
necessary. If the capacity of the vessel is not
considered sufficient for this, or for any other reason,

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isar -

Installation and Servicing

GENERAL

SYSTEM REQUIREMENTS - CH (continued) and Hot Water

an additional vessel MUST be installed on the return
to the boiler.

Guidance on vessel sizing is given in Frame 3.

5. Filling. The system may be filled by the following method:

a. Through a temporary hose connection from a 'draw-off'

tap, supplied from a service pipe under mains pressure.
Where the mains pressure is excessive a pressure
reducing valve must be used to facilitate filling.
When installing the filling device it must be connected as
shown below, to fully comply with the water regulations.
This may involve the fitting of an additional WRAS
approved isolator valve to the mains supply.

i. Thoroughly flush out the whole system with

cold water.

ii. Fill and vent the system until the pressure

gauge registers 1.5 bar and examine for leaks.

iii. Check the operation of the safety valve by

raising the water pressure until the valve lifts.
This should occur within 0.3 bar of the preset lift
pressure.

iv. Release water from the system until the

minimum system design pressure is reached;
1.0 bar if the system is to be pre-pressurised.

Water Flow Rate and Pressure Loss

Max CH Output

23.4

(Btu/h)

(80 000)

Water flow rate

l/sec

0.37

(gal/min)

4.8

Temperature Differential

(

(27)

Head available for

m.w.g.

2.3

system pump.

(ft.w.g.)

7.5

DOMESTIC HOT WATER

1. The domestic hot water service must be in accordance

with BS 5546 and BS 6700.

2. Refer to Table 1 for minimum and maximum working

pressures.

3. The boilers are suitable for connection to most types of

washing machine and dishwasher appliances.

4. When connecting to suitable showers, ensure that:

a. The cold inlet to the boiler is fitted with an approved

anti-vacuum or syphon non-return valve.

b. Hot and cold water supplies to the shower are of equal

pressure.

CH Return

Ecl 6053

Hose unions

Mains

water supply

Temporary hose

(disconnect after filling)

Additional

stop valve

Double check valve

assembly

(

note direction of flow

)

The boiler does not normally need a bypass but at least some
radiators on the heating circuit, of load of at least 10% of the
minimum boiler output, must be provided with twin lockshield
valves so that this minimum heating load is always available.
See note regarding thermostatic radiator valves on page 10.

Note. Systems incorporating zone valves which could
completely cut off the flow through the system must also
include a bypass.

BALANCING

1. Set the programmer to ON.

Close the manual or thermostatic valves on all radiators,
leaving the twin lockshield valves (on the radiators referred
to above) in the OPEN position.

SYSTEM BALANCING

Turn up the room thermostat and adjust these lockshield
valves to give boiler flow and return temperatures not
more than 20

C apart.

These valves should now be left as set.

2. Open all manual or thermostatic radiator valves and

adjust the lockshield valves on the remaining radiators,
to give around 15

C temperature drop at each radiator.

3. Adjust the room thermostat and programmer to

NORMAL settings.

5. Hard Water Areas

Where the water hardness exceeds 200mg/litre, it is
recommended that a proprietary scale reducing device is
fitted into the boiler cold supply within the requirements of
the local water company.

IMPORTANT

Provision MUST be made to accommodate the expansion of
DHW contained within the appliance, if a non-return valve is
fitted to the DHW inlet.

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